WO1995016835A1

WO1995016835A1 - Insulated construction form element, and reinforcement therefor, and wall construction

Info

Publication number: WO1995016835A1
Application number: PCT/CA1994/000698
Authority: WO
Inventors: Roland H. Liebregts
Original assignee: Liebregts Roland H
Priority date: 1993-12-17
Filing date: 1994-12-16
Publication date: 1995-06-22
Also published as: CA2111801A1; AU1270395A

Abstract

A hollow construction form element (10) for use in the erection of construction components of poured flowable construction materials (M), the element (10) acting as formwork for pouring and containing of the materials (M) and thereafter acting as thermal insulation, the element having an inner formwork panel (20), an outer formwork panel (22), at least one of the inner and outer formwork panels (20, 22) being formed of rigid mouldable thermal insulation material, the panels (20, 22) having interlocking upper and lower formations, a plurality of thermoplastic fire resistant cross members (60) extending between the inner and outer formwork panels (20, 22) and defining inner and outer ends, and top and bottom edges, embedment formations (72, 74) formed on at least one of the inner and outer ends of the cross members (60), embedded in the at least one of the inner and outer formwork panels (20, 22), and, hollow spaces (66) defined between the formwork wall panels, and above and below the top and bottom edges of the cross members (60), to permit flow of the pourable material (M). A plurality of vertical dovetail channels (34) are provided for water drainage or for improving the anchorage of architectural coatings to the wall surface. Also disclosed is a reinforcing framework (52) for use in making such hollow construction form elements (10), and a wall construction (W) employing such construction form elements (10).

Description

INSULATED CONSTRUCTION FORM ELEMENT. AND REINFORCEMENT THEREFOR. AND WALL CONSTRUCTION TECHNICAL FIELD

The invention relates to an insulated hollow construction form element, made of thermal insulation material, which receives material such as concrete, and to a frame for incorporation in such a form element. BACKGROUND ART

In conventional construction techniques, a wall made of castable concrete material is usually first of all defined by two panels of formwork erected side by side, and concrete is then poured in the formwork. Thermal insulation if used is usually applied by attaching to the concrete, either on the inside, or on the outside.

It has been proposed in the past to provide hollow blocks made of thermal insulation material to replace the formwork. The blocks actually defined the formwork. Since the blocks were formed of thermal insulation material, the wall was fully insulated both inside and out.

However with certain of these proposals there have been unforseen problems. There must be some junction structure extending transversely through the block, at intervals, to hold the two block walls together. In the past both the inner and the outer block walls, and the transverse junctions, have been moulded integrally of insulation materials. It is apparent that there will be openings extending completely through the concrete, at numerous points where the transverse junctions of the blocks extend through from one side to the other. Water will find it's way through the wall at these openings. Also these openings, constitute a fire hazard. In U.S. Letters Patent 4,731,968, inventor D. Obino, Issued March 22, 1988, it has been proposed to manufacture separate inner and outer walls block walls, and then to join the separate inner and outer walls together by inserts of sheet metal such as steel. However, sheet metal creates heat transfer problems. DISCLOSURE OF THE INVENTION

With a view to overcoming these conflicting problems the invention comprises a hollow construction form element for use in the erection of construction components of poured flowable construction materials, said element acting as formwork for pouring and containing of said materials and thereafter acting as thermal insulation for said construction component, said element comprising, an inner formwork panel, an outer formwork panel, at least one of said inner and outer formwork panels being formed of rigid mouldable thermal insulation material, a plurality of thermoplastic non¬ flammable cross members extending between said inner and outer formwork panels at spaced intervals therealong and defining inner and outer ends, and top and bottom edges,inner axial junction strips extending between adjacent inner ends, and outer axial junction strips extending between adjacent outer ends, of said plurality of cross members, embedment formations formed on at least one of said inner and outer ends of said cross members, said embedment formations being embedded in said at least one of said inner and outer formwork panels, and, hollow spaces defined between said inner and outer formwork wall panels, and hollow spaces being defined above and below said top and bottom edges of said cross members, whereby to permit flow of said pourable material therearound.

The invention further comprises a wall formed of such construction form elements with said outer panels on the exterior of said wall, and water permeable mesh material secured to said outer panel on its exterior side, so that water may pass through and flow down said channels.

Another aspect of the invention comprises a support frame for incorporation in a construction form element in accordance with the invention, the support frame having a plurality of transverse junction portions, and a plurality of upright bracing struts, the bracing struts preferably having interlocking fastening means at their upper and lower ends for securing the courses of blocks together, and the frame xurther incorporating axial spaced apart parallel bracing members connecting said transverse junction members and forming the same into an integral frame.

The various features of novelty which characterize the invention are pointed out with more particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its use, reference should be had to the accompanying drawings and descriptive matter in which there are illustrated and described preferred embodiments of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a perspective illustration of a portion of a wall illustrating the use of one embodiment of construction form elements in accordance with the invention, portions being cut away;

Figure 2 is a perspective of a single construction form element of Figure 1;

Figure 3 is a perspective illustration of a single construction form element modified for use to build a corner;

Figure 4 is a perspective illustration of a frame, used for incorporation in the construction form element to hold the two side panels together;

Figure 5 is a cut-away perspective of the element of Figure 2;

Figure 6 is an enlarged perspective view of portions of the construction form element of Figure 5;

Figure 7 is a section along line 7-7 of Figure 6;

Figure 8 is a upper plan view looking downwardly along the upper edge of one side panel of the element of Figure 5;

Figure 9 is an exploded sectional view showing the upper edge of one side of one element, and the under side of the next adjacent higher element prior to assembly, and,

Figure 10 is a perspective illustration showing the manner of interlocking engagement achieved by fitting the interlocking formations of the two elements of Figure 9 together. MODES OF CARRYING OUT THE INVENTION

Figure 1 illustrates in this example a construction form element or block 10, open at each end, forming a wall W, and in which a pourable material M may be poured. Reinforcing rods (not shown) may be laid both horizontally and introduced vertically.

Also shown in Figure 1 is the mesh screen material S attached on the outer side of wall W, and the weeping tile, or exterior drain T, which function as described below. Figures 2, 5 and 6, show an inner formwork panel 20 and an outer formwork panel 22. The inner panel 20 has an outer surface 24, and an inner surface 26 facing towards the interior of the block or element. The inner surface 26 is formed with a plurality of spaced apart keying formations 28 (Figure 5) .

The outer panel 22 has outer surface 30 facing outwardly from the element, and an inner surface 32 facing inwardly towards the interior of the element.

The outwardly facing surfaces 24 and 30 of panels 20 and 22 have groups of generally vertical liquid drainage channels 34 (Figure 5) formed therein. Planar portions 36 are formed for purposes to be described.

The inwardly facing surface 32 of the outer panel 22 has keying formations 38 (Figure 9) similar to the keying formations 28 on the inner panel 20.

The panels 20 and 22 define, male upstanding sealing formations 40. Sealing formations 40 are of generally continuous sinusoidal shape, along either side, when viewed in plan, giving the male formations a generally semi- cylindrical shape.

Along the lower edges of the panels, female sealing recesses 44 are formed.

The recesses 44, when viewed upwardly in plan (Fig. 8), have a generally sinusoidal shape along their edges, corresponding to the sinusoidal semi-cylindrical shape of the male formations 40, and to receive the male formations 40. Sealing ridges 46 (Figure 8) are formed along the opposite end edges of such panels sealing grooves 48 are formed to receive the sealing ridges 46.

Additional sealing beads 50 are formed, so that when the ends of the blocks are squeezed together the beads will be deformed.

A junction frame assembly 52 (see Figure 4) is provided. Frame 52 is shown in the partially cut away view of Figure 5 and the enlarged view of Figure 6. It has cross members 60 located between respective inner and outer panels 20 and 22, at intervals. The block may be about 120 cm long, and may have four junction members 60 equally spaced. The end junction members are spaced from their ends by a distance equal to one half the spacing between members 60. Such junctions 60 may also be used at each end of the block.

Junction members 60 comprise upper junction portions 62 and lower junction portions 64. Each of junction portions 62,64 is of generally planar construction, and the two portions 62 and 64 are located in vertical planes which are spaced apart axially and define spaces 66 therebetween.

Recesses 68 are formed in upper junction portions 62 to act as guides for reinforcing rods (not shown) . A stiffening rib 70 (Figure 6) extends generally vertically on one side of the upper and lower portions 62,64. At each end they are integrally formed with angled reinforcement portions 73, which join with generally Tee- shaped elongated upper and lower embedment formations 72,74, extending along vertical axes offset from one another (Fig.7) . The locations of the formations 72,74 is such that they will lie median to or slightly to the exterior of each of the panels 20 and 22 respectively.

The embedment formations 72,74 are in turn united by means of buttresses 76, flanges 77 and generally horizontal bracing strips 78. The bracing strips 78 and the embedment formations 72,74 and flanges 77 and the upper and lower portions 62 and 64 are all moulded integrally of fire resistant thermoplastic material having a fire rating appropriate to the type of building.

The frames comprising the junction members and embedment formations and bracing strips, are first of all injection moulded in a single mould out of fire resistant plastic material. They are then placed in a larger mould, the polystyrene material is then filled into that mould, and the two side panels 20 and 22 are thus formed around the embedment formations 72,74 and bracing strips 78 of the frames.

The planar portions of the block 36 are located so as to register with the locations of the upper and lower embedment portions 72 and 74.

The upper embedment portions 72 are located so as to register with the male sealing formations 40. The lower embedment formations 74 are located so as to register with the female sealing recesses 44.

The upper embedment formations 72 have locking detents 80 and the lower embedment formations 74 have interlocking recesses 82. Stop bars 84 are formed on the upper embedment formations 72 adjacent the detents 80.

When an upper block is placed on a lower block, the detent on the upper embedment formation 72 of the lower block yields on one side, while the lower embedment formation 74 on the underside of the upper block yields in the other direction, permitting the detent 80 to pass into it's locking recess 82.

Indexing marks on the block comprise larger domes 90, located centrally with respect to the planar portions 36, and smaller domes 92 located along the ridges defined between the channels 34.

The larger domes 90 register with the buttresses 76 at the intersection between the bracing strips 78 and the upper and lower embedment formations 72,74. Thus the larger domes indicate the point of maximum strength for inserting fastenings. Corner blocks 96 are formed, having two block portions formed together at 100 and defining a wall corner.

Corner blocks 96 would be moulded in two sizes, so as to accommodate the interlocking courses of the regular blocks, at each corner.

In operation, the frames are moulded separately in an injection moulding plant.

The frames, are nestable, and may be shipped in an economical manner. At the building site, the construction form elements 10 will be laid up in courses (Figure 1) . Corners may be formed using the corner blocks 96 of Figure 3. Reinforcing bars (not shown) will be inserted where necessary.

The castable material, i.e. concrete, will then be poured in the cavities between the inner and outer panels. Once the concrete is cured, an exterior mesh filter screen S (Figure 1) is secured to the outer surface of the outer panels, to prevent backfill and earth from filling the channels 34 in the outwardly facing panels. As moisture penetrates the earth and reaches of the outer panels, it will pass through the filter mesh screen S and into the channels 34 in the of the outer panels. The water can freely run down the exterior of the panels until it reaches the drainage tile and/or pipe T, at which point it may be carried off to drainage.

Drywall or other finish may be secured to the outer surface of the inner panel, by using suitable fasteners passing through the high strength locations indicated by the domes 90 and 92. Where plaster is used, channels 34 enhance the anchoring.

The foregoing is a description of a preferred embodiment of the invention which is given here by way of example only. The invention is not to be taken as limited to any of the specific features as described, but comprehends all such variations thereof as come within the scope of the appended claims.

Claims

CLAIMS;

1. A hollow construction form element (10) for use in the erection of construction components of poured flowable construction materials (M) , said element (10) acting as formwork for pouring and containing of said materials during curing and thereafter acting as thermal insulation for said construction component, said element (10) characterized by: an inner formwork panel (20) ; an outer formwork panel (22) ; at least one of said inner and outer formwork panels

(20,22) being formed of rigid mouldable thermal insulation material; a junction frame assembly (52) having a plurality of thermoplastic fire resistant cross members (60) extending between said inner and outer formwork panels (20,22) at spaced intervals therealong, and bracing strips (78) extending between adjacent ends of said plurality of cross members (60) ; embedment formations (72,74) formed on said inner and outer ends of said cross members (60) , said embedment formations (72,74) being embedded in said inner and outer formwork panels (20,22), and, hollow spaces (66) defined between said inner and outer formwork panels, and hollow spaces (66) being defined above and below said cross members, whereby to permit flow of said pourable material (M) .

2. A hollow construction form element (10) as claimed in Claim 1 and including upper and lower edges, and end edges, defined by said inner and outer panels (20,22), and interlocking sealing members (40,44,46,48), formed thereon, for sealing between adjacent said form elements (10) .

3. A hollow construction form element (10) as claimed in Claim 2 and including keying formations (28) on inner surfaces of said inner and outer formwork panels (20,22) , for embedment in said cast material (M) whereby to secure said inner and outer formwork panels (20,22) to said cast material (M).

4. A hollow construction form element (10) as claimed in Claim 2 and including liquid drain channels (34) formed in the outer surface of said outer formwork panels (22) .

5. A hollow construction form element (10) as claimed in Claim 2 and wherein said sealing members (46,48) at said end edges further include complimentary means (50) , adjacent blocks to one above the other.

6. A hollow construction form element (10) as claimed in Claim 1 wherein said cross members (60) define upper and lower wall portions (62,64), located in respective upper and lower planes offset from one another.

7. A hollow construction form element (10) as claimed in Claim 6 wherein said cross members (60) define a spacing (66) between said upper and lower wall portions.

8. A wall (W) formed of hollow construction form elements (10) having inner and outer panels (20,22) defining a hollow interior, and a castable material (M) filling the same, and said form elements (10) comprising; liquid drain channels (34) in said outer panels (22) on the exterior of said wall (W) , and, water permeable mesh material (S) secured to said outer panel (22) on its exterior side, said material (S) being adapted to prevent passage of earth and fill into said liquid drain channels (34) in said outer panel (22) whereby water permeating said earth and fill may pass through said mesh material (S) and flow freely down said drain channels (34) .

9. A frame (52) for incorporation in a hollow construction form element (10) for use in the erection of construction components of poured flowable construction materials (M) , said element (10) acting as formwork for pouring and containing of said materials (M) during curing and thereafter acting as a thermal insulation for said construction component, said element (10) having an inner formwork panel (20) , and an outer formwork panel (22) , and said frame (52) comprising; a plurality of thermoplastic fire resistant cross members (60) adapted to extend between said inner and outer formwork panels (20,22) at spaced intervals therealong and defining inner and outer ends, and top and bottom edges; inner and outer axial bracing strips (78) extending between adjacent inner and outer ends of said plurality of cross members (60) ; embedment formations (72,74) formed on said inner and outer ends of said cross members (60) , said embedment formations (72,74) being adapted to be embedded in said inner and outer formwork panels (20,22), and, spaces (66) defined above and below said top and bottom edges of said cross members (60) , whereby to permit flow of said pourable material (M) therearound.